Gauge system

ABSTRACT

Gauge system, including methods and apparatus, for positioning workpieces to be processed. In some embodiments, the gauge system may have a plurality of stops for positioning the end of a workpiece at distinct distances from a processing station. In some embodiments, the plurality of stops may be arrayed along a rail assembly having an adjustable length.

CROSS-REFERENCE TO PRIORITY APPLICATION

This application is a continuation of U.S. patent application Ser. No.11/711,497 filed Feb. 26, 2007 which is incorporated herein by referencein its entirety for all purposes.

CROSS-REFERENCES TO RELATED MATERIALS

This application incorporates by reference the following U.S. patents:No. 4,596,172; No. 4,901,992; No. 5,042,341; No. 5,444,635; No.5,960,104; No. 6,216,574; No. 6,631,006; No. 6,886,462; No. 6,898,478;No. 6,941,864; No. 7,080,431; No. 7,168,353; and No. 7,171,738.

This application also incorporates by reference the following U.S.provisional patent application: Serial No. 60/839,661.

This application also incorporates by reference the following U.S.patent applications: Ser. No. 10/645,827; Ser. No. 10/897,997; Ser. No.10/958,690; Ser. No. 11/140,541; and Ser. No. 11/492,703.

BACKGROUND

Automated gauge systems may facilitate positioning workpieces, such asstock lumber, relative to a saw. An operator inputs a desired length ofa product, and the system automatically positions a stop (e.g., a fence)such that the stop is spaced from the saw by the desired length.Accordingly, a workpiece abutted at its end against the stop andproperly aligned with a rail can be positioned quickly and accuratelyfor sawing to create the product.

In order to position the stop for both long and short products, thesystem may have a relatively long drive mechanism that drives movementof the stop. For example, a gauge system that can cut lumber to generateproducts of up to ten feet in length may have a drive mechanism and arail that are both about ten feet long. The drive mechanism and railthus may restrict the portability, storability, and/or maximum productlength of the gauge system.

SUMMARY

The present teachings provide a gauge system, including methods andapparatus, for positioning workpieces to be processed. In someembodiments, the gauge system may have a plurality of stops forpositioning the end of a workpiece at distinct distances from aprocessing station. In some embodiments, the plurality of stops may bearrayed along a rail assembly having an adjustable length.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 is a top view of an exemplary gauge system for positioningworkpieces to be processed, in accordance with aspects of the presentteachings.

FIGS. 2-5 are top views of another exemplary gauge system forpositioning workpieces to be sawed, with a workpiece disposed at variouspositions along a positioning axis of the system, in accordance withaspects of the present teachings.

FIG. 6 is a schematic view of an exemplary controller that may beincluded in the gauge systems of the present teachings.

FIG. 7 is a top view of another exemplary gauge system for positioningworkpieces to be processed, in accordance with aspects of the presentteachings.

FIG. 8 is a sectional view of a rail and a guide of the gauge system ofFIG. 7, taken generally along line 8-8 of FIG. 7.

FIG. 9 is a sectional view of a rail and a driver of the gauge system ofFIG. 7, taken generally along line 9-9 of FIG. 7.

FIG. 10 is a sectional view of a rail of the gauge system of FIG. 7,taken generally along line 10-10 of FIG. 7 adjacent a stop of the rail.

FIG. 11 is a top, exploded view of a joint between rail frame sectionsof the gauge system of FIG. 7, taken generally at the position of therail shown in FIG. 10.

FIG. 12 is a top view of an exemplary rail including a pivotable stopthat accommodates workpieces with either a square end or an angled end,in accordance with aspects of the present teachings.

FIG. 13 is a top view of an exemplary gauge system with a folding rail,in accordance with aspects of the present teachings.

DETAILED DESCRIPTION

The present teachings provide a gauge system, including methods andapparatus, for positioning workpieces to be processed. The gauge systemmay have a rail with selectable stops. Alternatively, or in addition,the rail may have an extended (or longer) working configuration and amore compact (or shorter) storage configuration, for example,configurations created, respectively, by connecting and disconnectingframe sections of the rail. In some embodiments, the gauge system mayhave a drive mechanism with a range of travel substantially less thanthe measurement range of the system. Overall, the gauge systems of thepresent teachings may offer improved portability and/or storability,and/or a more compact drive mechanism, among others.

FIG. 1 shows an exemplary gauge system 20 for positioning workpieces tobe processed. System 20 may be a linear gauge that enables linearpositioning of a workpiece 22 along a positioning axis 24 such that oneor more sites 26 along the workpiece are selected for modification by aworkpiece processor 28 (and, optionally, 28′ and/or 28″), such as a sawor drill, among others, disposed at a processing station(s). Inparticular, the linear gauge may dispose the workpiece with a trailingend 30 (or a leading end 31) of the workpiece at a desired spacing orlinear dimension/distance 32 from workpiece processor 28. In someembodiments, the gauge system may include a plurality of workpieceprocessors. For example, the system may include workpiece processor 28and an additional workpiece processor 28′ both disposed adjacent thesame end of the driver. Alternatively, or in addition, the system mayinclude workpiece processor 28 and an additional workpiece processor 28″that flank the driver downstream and upstream of opposing ends of thedriver.

System 20 may accomplish positioning via a controller 34, a driver (adrive mechanism) 36, and a rail assembly (a rail) 38 carrying two ormore stops 40 (here, stops labeled as A-C). The controller may be incommunication, indicated at 42, with the driver for operation of thedriver. The driver may be mechanically coupled to the rail assemblyand/or the stops, for example, via a coupling arm 43 or other couplingstructure. Accordingly, the controller may control movement, indicatedat 44, of the rail assembly and/or stops parallel to positioning axis24, by sending control signals to the driver. In particular, thecontroller may receive one or more user inputs or signals related toworkpiece processing, such as desired processing sites relative toworkpiece ends, a cut list (e.g., the length (and, optionally, thenumber) of products to be produced), defect position(s), the length ofthe current workpiece and/or of stock to be used, etc. Then, based onthe inputs, the controller may operate the driver so that the railassembly and/or stops are moved appropriately. The rail assembly and/orstops may be moved before and/or after the workpiece is aligned with therail assembly (and/or engaged with a stop). In some embodiments, thesystem also may include a secondary or fixed rail 45 that is alignedwith movable rail assembly 38 and disposed upstream or downstream of themovable rail assembly, such as positioned on the other side of workpieceprocessor 28, as shown here.

Stops 40 may be structured for alternative engagement of the workpiece'send at discrete locations along the positioning axis. The stops thus maybe arrayed along a rail frame 46 of the rail assembly, generally atpredefined axial positions of the rail frame. In addition, each stop maybe movable relative to the rail frame, indicated here by double-headedmotion arrows oriented orthogonally to processing axis 24. Each stop mayhave a deployed or working configuration, indicated at 47 for stop C.Some or all of the stops also may have a retracted configuration,indicated at 48 and 49, respectively, for stops A and B. Stops may bemovable when urged toward the rail frame, such as by engagement with aretraction surface 50 of a stop (see stop A). However, stops may remainstatic or fixed in position when urged parallel to the rail frame (i.e.,parallel to the positioning axis), such as when engaged via a stopsurface 52 of the stop. Workpiece 22 thus may be aligned with the railframe, such as manually, by abutment of a side 54 of the workpiece witha side surface 56 of the rail frame and/or with retraction surface 50 ofone or more retracted stops (e.g., stops A and B in the presentillustration). Furthermore, trailing end 30 of the workpiece may beengaged with the stop surface of a stop (e.g., stop C in the presentillustration) to position the workpiece end along the positioning axis.

Controller 34 may control positioning of the rail assembly according towhich stop is selected for axial positioning of the workpiece. The stopmay be selected by a user and communicated to the controller and/or thestop may be selected by the controller and communicated to the user,such as stop identity indicated on a display 60 (“STOP C”). (The stopselected by a user also may be marked adjacent the stop by the user orvia a signal from the controller, or indicated on the controller displayas a reminder to the user).

The gauge system may include any suitable support(s) to support and/orguide system components. For example, the guide system may include asupport platform 62, such as a table (e.g., a folding table), to supportand/or hold the processor, driver, controller, workpieces, and/or railassembly. Furthermore, the gauge system may include one or more guides64 to direct longitudinal movement of the rail assembly and/or stops,for example, by restricting lateral movement of the rail assembly (suchas horizontal and/or upward movement transverse to the positioningaxis).

Driver 36 may have a linear range of travel, indicated at 66, that issubstantially shorter than the length of the rail assembly and/or thearray of stops. In particular, a sufficient range of travel may beapproximately the distance between adjacent stops, because this range oftravel allows stops to be positioned at a continuous range of locationscorresponding to the collective range of travel of all the stops. Forexample, if the driver has a range of travel of about two feet, and iscoupled to a rail assembly with an array of four stops with adjacentstop pairs spaced by two feet, the positioning range of all the stopsmay be about eight feet (four stops multiplied by two feet/stop).Accordingly, the driver may be constructed to be substantially shorterthat the rail assembly. The rail assembly thus may provide the largestlinear dimension of the system in its working configuration (or the railassembly may provide the second largest linear dimension with thesupport platform being longest). To facilitate storage, shipping, and/orportability, the rail assembly further may have a storage configurationthat is substantially shorter and/or more compact than its working(operating) configuration. For example, the rail assembly may include aplurality of frame sections or modules 68. The sections/modules may beassembled lengthwise, generally end to end and aligned with each other,into an extended linear arrangement. The sections/modules also may bedisassembled or moved from the extended and/or linear arrangement. Moregenerally, the rail assembly may be converted from its storageconfiguration to its operating configuration by connecting framesections to each other, by unfolding a folded rail assembly, and/or bytelescoping nested frame sections.

FIGS. 2-5 show another exemplary gauge system 80 for positioningworkpieces, such as board 82, for cutting by a saw 84. System 80 may beconstructed with many of the features described above for system 20 ofFIG. 1, including a rail assembly with stops A, B, and C. The processingof board 82 shown in FIGS. 2-5 may be performed consecutively, forexample, to produce a collection of products from the board, and/or mayrepresent alternative processing configurations to produce only one (orat least less than all) of the products. For simplification, theprocessing configurations of FIGS. 2, 3, and 5 have the rail assembly atthe same longitudinal position.

FIG. 2 shows board 82 positioned axially by engagement with stop C.Stops A and B are retracted and a display 86 of the controller indicatesthe stop selected for use (e.g., the stop selected by the controllerand/or by a user of the system). Saw 84 may move transversely, indicatedat 88, to produce a cut 90 that is relatively far from an engaged end 92of the board.

FIG. 3 shows board 82 positioned axially by engagement with stop B.Selection of stop B by the controller and/or user is displayed by thecontroller at 93. The board may be sawed, indicated at 94, to produce ashorter product and/or to cut the board closer to end 92 than in FIG. 2.

FIGS. 4 and 5 show board 82 positioned axially by engagement with stop Adisposed at two distinct axial positions. Selection of stop A by thecontroller and/or the user is displayed at 95. In FIG. 4, the driver hasmoved the rail assembly farther away from the saw, relative to FIG. 3,indicated by an arrow at 96. The board may be sawed, indicated at 98 and100, respectively, to produce even shorter products and/or to cut theboard closer to end 92 than in FIGS. 2 and 3. In general, a workpiecemay be sawed repeatedly by engaging the end of the workpiecesuccessively with the same stop and/or with different stops disposedprogressively closer to the saw station.

Further aspects of the present teachings are described in the followingsections, include (I) rails and stops, (II) drive mechanisms, (III)controllers, (IV) workpieces, (V) workpiece processors, (VI) supportsand guide structures, (VII) system operation, and (VIII) examples.

I. Rails and Stops

The systems of the present teachings may include a workpiece engagementstructure termed a rail assembly or rail. The rail assembly and/orportions thereof may be mechanically coupled to a driver for drivenaxial motion of the rail assembly (and/or portions, such as stops).Furthermore, the rail assembly may be configured to facilitatepositioning workpieces longitudinally, generally parallel to a long axisof the rail assembly, and/or at a predefined lateral location relativeto the rail assembly. The rail assembly may have any suitable structureconsistent with its intended function. Generally, the rail assemblyincludes a plurality of stops coupled to a frame.

A stop, as used herein, generally includes any physical structurecapable of extending laterally to the frame and configured to engage anend of a workpiece, to restrict axial movement of the workpiece. A stopthus may be or include a block, a bar, a rod, a screen, a plate, and/orthe like. In some embodiments, the stop may be replaced by a visibleindex that allows manually positioning a workpiece by sight rather thanby engagement.

The stop may be fixed or movable in relation to the frame. A movablestop may be capable of any suitable translational and/or pivotalmovement. Suitable translational movement may translate the stopparallel to the long axis of the frame (e.g., a stop that is movable andthen fixable axially along the frame) and/or transverse to the long axisof the frame (e.g., a stop that translates upward, downward, inward(away from the user), and/or outward (toward the user)). Suitablepivotal movement may pivot the stop about an axis parallel to the longaxis of the frame (e.g., see Example 1) and/or about an axis transverseto the long axis of the frame (e.g., see Example 2). Furthermore, thestop may pivot upward (for example, generally toward the top of theframe), downward (e.g., toward the bottom of the frame), and/orlaterally (e.g., toward and/or away from the frame).

Movement of the stop may position the stop between an extendedconfiguration and a retracted configuration. The retracted configurationmay be flush with the frame, such that a workpiece engages the frame,and/or may project from the frame, such that a workpiece is spaced fromthe frame by contact with the stop. The stop may be configured to beurged to the retracted configuration by engagement with a workpiece(e.g., a workpiece engaging the stop from a vertical position and/ormoving horizontally toward the frame, among others). The stop also oralternatively may be configured to be urged to the retractedconfiguration manually, that is, with a user's hand(s). For example, thestop may be structured to be gripped and pivoted out of the extendedconfiguration. The stop may be biased toward the extended or retractedconfiguration. A biasing mechanism, such as a spring (e.g., a coilspring, a leaf spring, an air spring, etc.) may be coupled to the stop,such that, for example, the spring returns to the extended configurationafter a retracting force is removed.

In some examples, the stop may be coupled to a driver that drivesmovement of the stop to the extended and/or retracted configurations.Accordingly, movement of the stops relative to the frame may becontrolled by the controller, to automate stop extension/retraction.

In some examples, the extended and retracted configuration of each stopmay be sensed by a sensor. The sensor may be, for example, a mechanical,magnetic, electric, and/or optical sensor. The sensor may be arranged incommunication with a controller of the system, thereby allowing thecontroller to determine which stop(s) is retracted and which stop(s) isextended at a given time. Accordingly, the controller may use thisinformation about stop configurations to determine, for example, if auser has positioned a workpiece properly (i.e., selected the proper stopfor engagement with the end of a workpiece) and/or to inform thecontroller of the stop selected by the user (and thus the stop for whichsubsequent driver movement, if any, should be calculated).

The stop may include a detent mechanism that retains the stop in anextended and/or retracted configuration. The detent mechanism mayinclude, for example, a projection that fits into a depression, amovable pin received in a hole, a threaded fastener mechanism, and/orthe like.

A rail assembly may have any suitable number of stops. Generally, therail assembly has at least two, three, or four stops. However, in someembodiments, the rail assembly may have only one stop. The number may beadjustable, for example, by extending the frame by addition of one moreadditional frame modules and associated stop(s) and/or by addition (orremoval) of a stop to (or from) a frame without changing the frame'slength.

The stops may have any suitable arrangement along a frame. The stops mayhave a uniform or nonuniform spacing between adjacent stops of an array.In addition, the stops may be disposed at opposing ends of the frame, atonly one end (e.g., the end farther from the workpiece processor (ifperforming single-ended processing), and/or at any suitable intermediatepositions. Furthermore, a stop may be disposed generally between framesections, for example, at a joint between the sections, and/orintermediate to the ends of a frame section. If intermediate, thesection may have one, two, or more intermediate stops. The stops may bearranged or arrangeable in an array, for coupled motion driven by adrive mechanism and/or may be movable independently and selectively bythe drive mechanism parallel to the positioning axis.

The stops may be distinguishable visually to enable a user to select anappropriate stop for abutment with a workpiece. For example, the stopsmay have distinct associated indicia (e.g., distinct colors, shapes,symbols, alphanumeric characters, textures, etc.) to allow easyidentification of each stop. In some embodiments, the stops may haveassociated lights that are operated by the controller to indicate whichstop is to be used for positioning a workpiece. In some embodiments, theindicia may be provided by a frame section adjacent each stop. However,in some examples, the stops and/or frame sections may lack indicia, sothat the user identifies and distinguishes the stops according to theirrelative positions along the rail assembly (e.g., by counting).

The frame may have any suitable number and arrangement of framesections. The frame may have a single frame section or a plurality offrame sections that couple to one another. The frame sections may be atleast approximately of the same length and/or may have differentlengths. Furthermore, the frame sections may be structured as modulesthat can be assembled in various numbers and/or combinations to createframes of different lengths and/or with different stop positions and/orspacings. Each section/module may include one or more stops or may haveno stops.

The frame sections may couple to one another by any suitable coupling.The coupling may be relatively permanent such that the sections areintended to remain assembled. Alternatively, the coupling may beintended to be uncoupled partially (e.g., see Example 3) or completely(e.g., see Example 1) between uses, if desired, to allow the system toassume a more compact (less extended) configuration, such as to betransported more readily to/from a worksite or for placement intostorage. Partial uncoupling may change the axial and/or angulardisposition of frame sections with or without completely separating thesections. Complete uncoupling may allow the sections to be separatedcompletely. Exemplary coupling structures may include complementarymating structure, fasteners, a snap fit, a telescoping arranged, ahinged (folding) arrangement, etc.

Further aspects of stop structures, rails, and multi-stop arrangementsalong the rails that may be suitable for the processing systems of thepresent teachings are described in the patents and patent applicationsidentified above in the Cross-References, which are incorporated hereinby reference, particularly U.S. Pat. No. 4,901,992; and U.S. Pat. No.6,216,574.

II. Drive Mechanisms

The gauge systems of the present teachings each may include any suitablenumber of drive mechanisms. Each drive mechanism may be configured tomove the rail assembly (and/or portions thereof, such as the stops),workpieces, workpiece products, a processing station(s), a processingelement of a processing station, and/or the like. Drive mechanisms maybe configured to move the rail assembly, stops, workpieces, products,stations, and/or station elements translationally and/or pivotally,among others.

Operation of all or a subset of the drive mechanisms of a gauge systemmay be controlled by a controller (e.g., a computer) and/or a user. Acontroller thus may control when a drive mechanism is actuated (movementstarts), de-actuated (movement stops), the speed of the drive mechanism,acceleration of the drive mechanism, the direction of motion of thedrive mechanism, and/or the like. The drive mechanism may include anencoder that informs the controller of the position, speed, velocity,and/or acceleration, among others, of the drive mechanism. In someexamples, one or more of the drive mechanisms may be user controlled,such as by operation of a switch or other user control.

Each drive mechanism may include a motor and a mechanical linkage thatcouples operation of the motor to movement of a load. The load mayinclude a carriage and a rail assembly (e.g., see Example 1), a portionor all of a processing station, a set of stops, an individual stop, aworkpiece, and/or a product, among others.

Any suitable motor(s) may be used in the drive mechanism. Each motor maybe an AC or DC electric motor, or may be air- (or gas-) powered, amongothers. Exemplary motors may be single or multiphase, universal, servo,induction, synchronous, stepper, and/or gear motors, among others. Eachmotor may be rotary or linear.

The drive mechanism may employ any suitable linkage to a load. Exemplarylinkages may include a belt(s), a screw(s), a gear(s) (e.g., a wormgear), a chain(s), a cable(s), a pulley(s), a rod(s), a rack and pinion,and/or the like. The linkage also may include a guide structure or trackthat directs and/or facilitates sliding movement of the load.Accordingly, the guide structure or track may include bearings or otherelements that promote sliding.

Workpieces may be moved manually within the gauge systems of the presentteachings and/or their movement may be driven. In some embodiments,workpieces may be driven along and/or transverse to a positioning axisby a workpiece drive mechanism. The workpiece drive mechanism may beconfigured to engage any suitable surface of a workpiece, such as atrailing end (as when a stop acts as part of a pusher mechanism) to pushthe workpiece, a face or side (e.g., using a conveyor belt or conveyorwheels, among others) to carry or propel the workpiece, and/or a leadingend region, to pull the workpiece.

In some embodiments, the processing systems may include a drag mechanismthat affects the speed or acceleration/deceleration of a workpiece.Further aspects of drag mechanisms that may be suitable are described inU.S. patent application Ser. No. 11/140,541, which is incorporatedherein by reference.

Processed workpieces (products) may be moved away from processingstations by any suitable drive mechanism(s), such as manually or viadriven movement. In some examples, the workpiece drive mechanism alsomay be used to push workpiece products through an outfeed site aftertheir processing is complete. Alternatively, or in addition, productsmay be moved actively by a distinct product drive mechanism. The productdrive mechanism may include a conveyor, for example, to carry theproducts farther, generally along the positioning axis, to move theproducts forward beyond the processing station(s) and/or in a reversedirection along the axis. In some examples, the product drive mechanismmay include a pusher mechanism that engages a side of each product andpushes it transverse to the positioning axis, for example, down a rampand/or onto a conveyor. Further aspects of a return conveyor that may besuitable for the gauge systems of the present teachings are described inthe patents and patent applications listed above in theCross-References, which are incorporated herein by reference,particularly U.S. Pat. No. 7,168,353.

A processing portion of a processing station may be moved manuallyand/or by any suitable drive mechanism. For example, processing stationsmay include drive mechanisms that move processing portions of thestations relative to workpieces, such as into engagement with theworkpieces or into suitable proximity to the workpieces. The drivemechanisms thus may be operated, generally by computer control, to helpposition processing sites on a workpiece and/or to conduct processing.In some examples, processing stations, such as fixed printheads thatprint on workpieces, may lack a drive mechanism so that they arestationary during operation.

A processing station may use distinct drive mechanisms for driving aprocessing element in its basic operating motion (e.g., rotating acircular saw blade) and for driving processing of the element with theprocessing element (e.g., moving the rotating circular saw blade througha workpiece). Each of these drive mechanism may or may not be computercontrolled.

The systems of the present teachings may include a retention mechanism,such as a clamp mechanism or a clip that holds a workpiece in place asit is being processed by a processing station and/or moved by a drivemechanism. The clamp mechanism and/or clip may be operated manually.Alternatively, or in addition, the clamp mechanism may include a clampmember (or members) coupled to a drive mechanism, so that the clampmember can be moved into engagement with the workpiece to effectclamping, for example, when the workpiece is not moving, and can bemoved out of engagement with the workpiece to permit movement of theworkpiece by the workpiece drive mechanism. Operation of the clamp drivemechanism may be under computer control (i.e., automated).

III. Controllers

The gauge systems of the present teaching may include a controller(s)that controls operation of the system. The controller may, for example,receive input signals, process the input signals, provide outputsignals, interact with users, store information, control drivemechanisms (and/or other devices), and/or the like. The controller,which may be a computer, may automate any suitable aspects of a gaugesystem.

FIG. 6 shows a schematic representation of an exemplary controller 120that may be included in an exemplary gauge system. Controller 120 mayinclude a data manager 122 operatively coupled to a user interface 124(including, for example, a display 126 and an input device(s) 128).Exemplary input devices may include touch controls (e.g., a keyboard,keypad, buttons, a touchscreen, etc.), a joystick, a mouse, a reader forreading data from a digital storage device, and/or the like. The datamanager also may be operatively coupled to a printer 130. The printermay print any suitable data, such as a record of inputted, outputted,and/or product data. In some embodiments, the printer may be a labelprinter to print labels for workpiece products and/or may print directlyonto workpieces and/or products. Further aspects of printing labels andprinting directly onto workpieces are described in the patents andpatent applications identified above in the Cross-References, which areincorporated herein by reference, particularly U.S. Pat. No. 6,886,462,and U.S. Pat. No. 7,171,738.

A data manager, as used herein, generally comprises any device capableof receiving, processing, and outputting data, generally in the form ofelectrical, magnetic, and/or optical signals. Accordingly, the datamanager may include a microprocessor 132, a bus, memory, input/outputports, and/or processing instructions (e.g., hardware, firmware, and/orsoftware), among others. The data manager may receive inputs 134, andmay operate on the inputs via the microprocessor using one or morealgorithms or applications 136, to provide various outputs 138. Theinputs may, for example, relate to product data 140, system data 142,and/or workpiece data 144, among others. The outputs may, for example,relate to a stop selected and indicated, information presented on thedisplay, information printed by the printer, control signals sent todrive mechanism(s), and/or the like. Further aspects of a customizabledata manager that permits, for example, updating a processing list via auser interface, is described in U.S. Provisional Patent ApplicationSerial No. 60/839,661.

Any suitable product data 140 may be inputted about one or more desiredproducts to provide a product list. The product data may correspond tothe length of each desired product and, optionally, the absolute orrelative number desired of each product (a cut list); type(s) ofprocessing to be performed in formation of each product; a position(s)where processing should be performed for each product (e.g., relative toa leading and/or trailing end of a workpiece); order of processingoperations for each product; etc. The product data also may relate to aparticular product to be formed, for example, to allow a user to selectthe order of products to be formed, such as one-by-one after eachproduct is formed or after a set or products is formed. In someexamples, the product data may correspond to a destination for theproduct, such as a bin or chute, among others, to which the productshould be directed automatically, so that products are sorted afterprocessing. Further aspects of sorting products and salvage proceduresthat may be suitable are described in the patents and patentapplications identified above in the Cross-References, which areincorporated herein by reference, particularly U.S. Pat. No. 6,941,864;and U.S. Pat. No. 7,168,353.

In some embodiments, the controller or a data input device thereof, maybe separated (and/or disconnected) temporarily from other portions of aprocessing system, such as to allow a user to carry the controller ordata input device around a work site to input measurements. Accordingly,the controller and/or data input device may include a measuringmechanism, such as an optical (e.g., laser-based) measuring device.Further aspects of remote measurement are described in U.S. patentapplication Ser. No. 10/897,997, which is incorporated herein byreference.

Any suitable system data 142 may be inputted about how a gauge system isto operate. The system data may include, for example, calibration datarelated to the measured distance between one or more stops and aprocessing site defined by a processing station. In some examples, thecalibration data may be for only one stop if the spacing between stopsis predefined accurately. The system data also may include, for example,the configuration of the rail assembly (e.g., the number and/or type offrame sections included in the rail assembly), the position of stops,the spacing between stops, the number of stops, a selected speed of thedrive mechanism, user preferences about how the controller is tointeract with the user and/or conduct processing, and/or the like.

Any suitable workpiece data 144 may be inputted. The data may relate tothe type of workpiece, one or more characteristic dimensions (e.g., thelength, width, and/or thickness, among others) of the workpiece, gradeof workpiece material (e.g., high grade, medium grade, low grade, etc.),composition, shape, defect data (e.g., a defect position(s) along theworkpiece, degree of defect, etc.), color, and/or the like. Furtheraspects of inputting defect data and using the defect data to calculatean optimum plan for workpiece processing are described in the patentsand patent applications identified above in the Cross-References, whichare incorporated herein by reference, particularly U.S. Pat. No.5,042,341; U.S. Pat. No. 5,960,104; U.S. Pat. No. 6,631,006; and U.S.patent application Ser. No. 10/645,827.

Workpiece data 144 may be inputted through the action of a person (e.g.,a current user of the system) and/or automatically. Accordingly, theworkpiece data may be inputted through a computer interface, such as agraphical user interface, a keyboard, a keypad, a memory port, a networkconnection, etc. Alternatively, or in addition, the workpiece data,particularly one or more characteristic dimensions and/or defect dataabout of the workpiece, may be input through a controller-linkedmeasuring device. The measuring device may include an optical measuringdevice. Alternatively, or in addition, the measuring device may be anencoder-based measuring device that an operator can slide parallel tothe length of a workpiece and selectively actuate, for example, bypushing a button, to send information about the relative position of theworkpiece ends, one or more defects, and/or other workpiece features tothe controller. Exemplary measuring devices that may be suitable for usein the processing systems of the present teachings are described in thepatents and patent applications identified above in theCross-References, which are incorporated herein by reference,particularly U.S. Pat. No. 6,631,006; U.S. Pat. No. 6,898,478; and U.S.patent application Ser. No. 10/645,827.

Any suitable algorithms may be used to determine outputs. In someexamples, an optimizing algorithm may be used by the controller tocalculate an optimal plan for processing each workpiece. The optimizingalgorithm may, for example, compare the total length of a currentworkpiece, and/or the clear length(s) if defects are considered, to aproduct list, such as a cut list, to determine the best use of thecurrent workpiece in accordance with the cut list (and, optionally,which cut list products are produced). In other words, the algorithm mayselect processing positions (e.g., sawing positions) such that theprocessing system partially satisfies a processing list (e.g. a cutlist) with each processing operation. Further aspects of optimizationand algorithms that may be suitable for optimization are described inthe patents and patent applications identified above in theCross-References, which are incorporated herein by reference,particularly U.S. Pat. No. 4,596,172; and U.S. Pat. No. 5,444,635.

Whether or not the controller is informed of the length of a workpieceand/or the accuracy with which this information is conveyed may dependupon how the gauge system is processing the workpiece. In some examples,the gauge system may process a workpiece according to the position ofthe leading end of the workpiece (generally, the opposing end notengaged with a stop). Alternatively, the user may input no dataregarding the size of a workpiece to be processed. For example, the usermay input product data or select a product to be produced and thecontroller may assume that the user has a workpiece of sufficientlength. In some examples, the user may input a length characteristic ofstock workpieces being used. Further aspects of optimization andalgorithms that may be suitable are described above in the patents andpatent applications identified above in the Cross-References, which areincorporated herein by reference, particularly U.S. Pat. No. 4,596,172;U.S. Pat. No. 5,444,635; U.S. Pat. No. 7,171,738; and U.S. patentapplication Ser. 10/645,827.

IV. Workpieces

The gauge systems of the present teachings may facilitate processingworkpieces. A workpiece, as used herein, is any piece of material thatwill be, or is being, positioned for processing. Accordingly, aworkpiece may be in a raw or “unprocessed” form (before any processingby a system), in a partially processed form (during and/or after partialprocessing by the system), or in a fully processed form (afterprocessing of the workpiece by the system has been completed and/or theworkpiece has passed through the system). Each processing station of asystem thus may process the raw form of the workpiece, a partiallyprocessed form of the workpiece (such as a workpiece cut into smallerpieces or segments (a segmented form of the workpiece) and/or modifiedotherwise), or both. The processed form of a workpiece, as used herein,is termed a workpiece product or product. Although processed by a firstpass through the system, a product may be processed additionally outsidethe system or during a second pass through the system.

A workpiece may have any suitable composition. Workpieces thus may beformed of wood, metal, plastic, fabric, cardboard, paper, glass,ceramic, or a combination thereof, among others. The composition may begenerally uniform or may vary in different regions of a workpiece (e.g.,a workpiece with a wood body and a vinyl coating). Exemplary workpiecesare wood products, for example, sawn lumber, wood laminates, woodcomposites, etc. Other exemplary workpieces are metal sheets or strips.

A workpiece may have any suitable shape and size. Generally, theworkpiece is elongate, so that the workpiece can be positioned andprocessed relative to a positioning axis that is parallel to the longaxis of the workpiece. However, in some embodiments, the workpiece maynot be elongate and/or may not be oriented so that the long axis of theworkpiece is parallel to the positioning axis. The workpiece may haveany suitable length. Exemplary lengths are based on available lengths ofstock pieces, such as stock lumber of about two feet to twenty feet inlength, for the purpose of illustration. In some examples, the workpiecemay have a rectangular cross section, opposing ends, sides, and faces.One or both ends may be square or oblique (angled/beveled). Furthermore,the sides and faces may be planar or nonplanar.

A workpiece may be of generic stock or may be pre-processed according toa particular application, before processing with a gauge system. Forexample, the workpiece may be a standard piece of raw lumber.Alternatively, the workpiece, before processing by the gauge system, mayinclude one or more holes, grooves, ridges, surface coatings, markings,etc., created, for example, based on desired features of products to beformed by the gauge system. Further aspects of workpieces that may besuitable are described in the patents and patent applications identifiedabove in the Cross-References, which are incorporated herein byreference, particularly U.S. Pat. No. 6,631,006; U.S. Pat. No.7,080,431; and U.S. Pat. No. 7,171,738.

V. Workpiece Processors

The gauge systems of the present teachings each may include no workpieceprocessors, or may include one, two, or more workpiece processors,generally creating processing stations for processing workpieces. Theterm “processing,” as used herein, can be any action or set of actionsthat result in structural modification of a workpiece. A structuralmodification is any change in the shape, size, a surface aspect, and/orother property of a workpiece, for example, by removing material fromthe workpiece, adding material to the workpiece, deforming theworkpiece, and/or changing the molecular structure of the workpiece,among others. Accordingly, a processing station is any portion of agauge system that can effect processing of a workpiece. Each processingstation generally includes a machine or set of machines configured toperform a processing operation, and an associated space in which theprocessing can be performed on a workpiece. A system with two or moreprocessing stations may include distinct processing stations thatperform two or more different types of processing operations and/or thatcan perform the same type of processing operation at different positions(for example, at the same time).

A processing station may include a processing element that engages aworkpiece and/or ejects a material or projectile toward the workpiece.Exemplary processing elements that engage a workpiece may include ablade, a drill bit, a router bit, a pen, a tip, a scribe, a brush, etc.Exemplary processing elements that eject (or fire) a material orprojectile toward the workpiece, with, or more generally without contactbetween the workpiece and the processing elements, may include aprinthead, a sprayer, a dropper, a projectile gun, etc. (Exemplaryprojectiles may include spacers, fasteners, joint members (e.g., dowels,biscuits, butterfly locks, etc.), and/or the like. Processing elementsmay have any suitable disposition and/or direction of travel relative toa workpiece. For example, processing elements may be disposed above,below, laterally, and/or adjacent an end of the workpiece (and/or asegment thereof). Furthermore, processing elements may be movabletranslationally and/or pivotably, in any suitable direction, includingdownward, upward, transverse, oblique, and/or longitudinal motion, amongothers, relative to the workpiece. This motion may position theprocessing element at a suitable position along the length, width,and/or depth of the workpiece, and in some examples (e.g., drilling,sawing, and/or routing, among others), may introduce the processingelement into and/or through the workpiece. Accordingly, the processingelements may be configured to process faces, sides, and/or ends ofworkpieces.

Movement of processing elements, termed processing movement, to disposethe elements in operational position relative to workpieces, may becontrolled manually and/or via a controller. Processing elements alsomay have a basic repetitive operating motion, such as rotation,reciprocation, and/or travel along a looped path, among others, whichmay be actuated separately by an element driver, and also may bemanually or computer controlled.

The processing stations of a gauge system may have any suitablepositional, functional, and operational relationship. Two or more of theprocessing stations may be disposed upstream and downstream of oneanother, generally along a positioning axis (a processing path) of agauge system. In some cases, the two or more processing stationsgenerally may flank or oppose the ends of the drive mechanism and/orrail assembly for double-ended processing. Accordingly, the controllermay be configured to position a selected stop (and, optionally, one oftwo opposing engagement surfaces (sides) of the stop) relative to one orthe other of the processing stations. Further aspects of double-endedprocessing are described in the patents and patent applicationsidentified above in the Cross-References, which are incorporated hereinby reference, particularly U.S. Pat. No. 7,080,431; and U.S. patentapplication Ser. No. 11/492,703. Alternatively, or in addition, two ormore of the processing stations may have about the same position alongthe processing path, for example, when the processing stations occupysubstantially nonoverlapping positions around the workpiece. Theprocessing stations may have a fixed or adjustable positionalrelationship relative to one another (and/or to the workpiece),particularly along the processing path of the workpiece. Accordingly, insome examples, the processing stations may be movable to the sameposition in the processing path. The processing stations may performprocessing operations on a workpiece at any suitable relative times. Forexample, the processing stations may operate in a sequential manner onthe same region of the workpiece (e.g., forming a cavity in a regionwith a first station, and then placing a component in the cavity with asecond station), may operate at overlapping times on the workpiece(e.g., cutting a workpiece at a saw station as the workpiece is beingdrilled at a drill station), and/or may operate at non-overlapping timeson the workpiece (e.g., processing a workpiece using a station andduring a first time period (or a first set of intervals), while theworkpiece is moving, and processing the workpiece using another stationand during a second, nonoverlapping time period (or set ofnonoverlapping intervals), while the workpiece is not moving).Processing operations performed with two or more processing stations,and workpiece movement, each may be performed manually and/or may becontrolled by computer.

A processing station may be configured for removing material from aworkpiece, to change the shape, size, and/or a surface aspect of theworkpiece. Exemplary processing stations for removing material include asaw station (or another cutting station including a laser, knife, flame,electron beam, etc.) for cutting a workpiece, a router station forrouting/milling a workpiece, a scorer station for scoring the surface ofa workpiece, a sander station for smoothing the surface of a workpiece,a hole-forming or drill station for forming a hole in a workpiece, aborer station for widening a hole in a workpiece, a shearer station forshearing a workpiece, a deburrer station for deburring a cut end and/orother surface of a workpiece, a V-groove station for cutting a V-groovein a workpiece, a punch station for punching a hole in a workpiece,and/or the like.

A saw station may include any suitable type of saw, saw blade, bladeorientation, and blade movement. Exemplary blades may include circularblades, band blades, and/or reciprocating blades, among others. Theblades may be configured to perform crosscuts (generally transverse tothe length of a workpiece; e.g., chop saws), rip cuts (generally alongthe length of a workpiece; e.g., rip saws), miter cuts, dado cuts, anglecuts, nonlinear cuts, etc. The saw station thus may include a motor thatdrives the blade rotationally (e.g., circular saws), around a loop(e.g., band saws), and/or back and forth (e.g., reciprocating saws). Thedriven saw blade may be configured to be actuated for cutting aworkpiece by movement of the driven blade, in any suitable directionrelative to a workpiece, including translationally (e.g., a radial armsaw) and or along an arc through pivoting motion (e.g., a chop saw,using an upward and/or downward motion). Further aspects of formingdados that may be suitable for the systems of the present teachings aredescribed in U.S. patent application Ser. No. 10/958,690, which isincorporated herein by reference.

A drill station may include any suitable components and may operate byany suitable direction of approach to a workpiece. The drill station mayinclude a driver and a drill bit rotated by the driver. Positioning ofthe drill bit may be controlled manually or by computer. Thispositioning may be parallel to the long axis of the drill bit (tocontrol depth of drilling for through-holes or recesses), and/ortransverse to this axis. Accordingly, the depth of drilling may becontrolled, to form through-holes or recesses. Also, the transverse,longitudinal, and/or vertical position of hole formation on a workpiecemay be controlled, as may the angle of hole formation.

A processing station may be configured to add material to a workpiece,to change the shape, size, and/or a surface aspect of the workpiece.Exemplary processing stations for adding material include a printstation for adding one or more surface marks (an indicium or indicia) toa workpiece, a fastener station for adding a fastener to a workpiece(such as a nail, screw, bolt, rivet, bracket, hook, staple, dowel,biscuit, butterfly lock, spline, etc.), a coating station for adding asurface coating or fluid (e.g., paint, varnish, stain, sealant, glue,etc.) to a surface or surface region of a workpiece, a spacer stationfor adding a spacer element (e.g., a spacer ball, a block, a spline,etc.) to a workpiece, an assembly station that connects (e.g., joins)the workpiece with one or more other components, and/or the like.

A processing station may be configured to change the shape of aworkpiece by deformation of the workpiece. Exemplary deformation mayinclude bending, twisting, folding, compression, stamping, and/or thelike.

A processing station may be configured to change the molecular structureof a workpiece. Exemplary operations that may be used to change themolecular structure of a workpiece, either globally or locally in theworkpiece, may include heating, cooling, exposure to electromagneticradiation (e.g., visible light, infrared light, radiofrequency waves,microwaves, ultraviolet light, X-rays, gamma-rays, etc.) or particleradiation, soundwaves (sonic or ultrasonic), compression, and/or thelike.

Further aspects of processing stations that may be suitable aredescribed in the patents and patent applications identified above in theCross-References, which are incorporated herein by reference,particularly U.S. Pat. No. 7,171,738; and U.S. patent application Ser.No. 10/958,690.

VI. Supports and Guide Structures

The gauge systems of the present teachings may include various supportand/or guide structures that support, guide, and/or facilitate movementof workpieces, processing stations, and/or processing portions ofprocessing stations. For example, the support structures may include atable. The table may be foldable and/or may disassemble to increase theportability of the system. The table may include structures thatfacilitate and/or guide sliding, such as wheels, bearings, fixedrails/fences, and/or a slider, among others. One or more processingstations and/or a rail assembly may be coupled to the table or toadjacent support structures. Coupled components may be removable readilyfrom the table to increase the portability and storability of the gaugesystem.

VII. System Operation

The gauge systems of the present teachings may be operated in variouscombinations of manual and automated modes to process workpieces intoproducts. The modes may include manual or automated stop selection,manual or automated selection of a product to produce from a list ofproducts, manual or automated positioning of a workpiece relative to astop, manual or driven motion of the workpiece along a positioning axis,manual or automated processing after the workpiece is properlypositioned along the positioning axis, manual or automated labeling of aworkpiece or product, and/or the like.

VIII. Examples

The following examples describe selected aspects and embodiments of thepresent teachings, particularly exemplary gauge systems for processingworkpieces and components of the gauge systems. These examples and thevarious features and aspects thereof are included for illustration andare not intended to define or limit the entire scope of the presentteachings.

Example 1 Exemplary Gauge System

This example describes an exemplary gauge system 150 including anexemplary driver, rail assembly, and guide for the rail assembly; seeFIGS. 7-11.

FIG. 7 shows a top view of gauge system 150. The system may include adrive mechanism 152 that allows accurate positioning of a workpiece 154relative to one or more processing stations 156 (here, a saw station).The drive mechanism may be controlled by a controller that operates thedrive mechanism and a coupled rail assembly 158, to position the railassembly along a linear processing path 160. The rail assembly may havea plurality of stops 162, one of which may be selected for engagementwith the end of the workpiece (e.g., the selected stop indicated at164). The workpiece may be driven longitudinally by the drive mechanism(e.g., with the selected stop in engagement with an end of the workingand thus acting as a pusher). Alternatively, the workpiece may bepositioned manually in engagement with the selected stop, generallyafter the rail assembly has stopped moving and the selected stop isstatic.

Rail assembly 158 may include a frame 166 having a plurality of discreteframe component or rail sections 168 disposed between stops 162. Theframe may slide along a support, such as a table (see FIGS. 8-10).Accordingly, the frame and/or support may have wheels and/or bearingsthat facilitate sliding motion. Alternatively, or in addition, the framemay be guided by one or more guides 170 coupled to the support, forexample, attached fixedly to the support.

FIG. 8 shows a sectional view of frame 166 and guide 170 taken generallyalong line 8-8 of FIG. 7. The guide (or guides) be mounted on a support171 (here, using fasteners) and may include a guide projection 172projecting upward from the base or body of the guide. The guideprojection may be received in a longitudinal track or groove 174 formedin the underside of the frame and extending at least a portion or all ofthe length of the frame. The guide projection, which may be static, thusmay guide movement of track 174 as the track is moved with the frame. Insome examples, the guide (and/or the frame) may include a wheel orbearing(s) to facilitate movement and/or to reduce friction. In otherembodiments, the support (e.g., a table) and/or an attachment theretoalso may provide a support track (e.g., a ridge or groove) in, on, orover which the frame may ride. The support track may extend any suitableportion of the length of the support and may be continuous orinterrupted by one or more breaks in the track.

FIG. 9 shows a sectional view of frame 166 and a screw-based drivemechanism 152 taken generally along line 9-9 of FIG. 7. The drivemechanism may include a housing 176 and a lead screw 178 coupledrotatably to the housing. The drive mechanism also may include aninternally threaded carriage 180 coupled to the lead screw forrotation-driven axial motion of the carriage along the lead screw andthus the housing. The carriage may include an arm 182 that extends outof an opening 184 in the housing to frame 166 of the rail assembly. Thearm may be attached to the frame, indicated at 186, such that the armand the frame move together. In some embodiments, the arm may beconnectable to the frame alternatively via distinct rail sections and/orvia two or more alternative positions along a rail section. In someembodiments, the arm may not attach to the frame, but to a sub-framecarrying the stops. Accordingly, portions of the frame, such as analignment surface 188 that may engage the side of a workpiece may bestatic during operation of the drive mechanism.

FIG. 10 shows a sectional view of frame 166 and stop 162 taken generallyalong line 10-10 of FIG. 7; FIG. 11 is an exploded view taken from abovethe frame at about the same position. Frame sections 168 may be coupledto one another via one or more bridge elements, such as rods 190, 191received in respective holes 192, 193 (see FIGS. 8, 10, and 11)extending into frame sections from the ends thereof to form a joint 194(see FIG. 11). A lock mechanism 196 may be actuated to restrictuncoupling of the frame sections at the joint. The lock mechanism may,for example, be a latch mechanism including a draw latch 198 on one sideof the rail joint and a latch strike 200 on the other side of the joint.In some embodiments, the lock mechanism may be operated manually, suchas via a handle connected to the draw latch, to lock and unlockconnection of adjacent frame sections.

One or more bushings 202, 203 may serve as spacers and/or stop couplers(see FIGS. 10 and 11). For example, the bushings may be disposed on rods190, 191 to separate the ends of the frame sections and thus act asspacers. A stop member 204 (forming stop 162) may be received on bushing202 for pivotal movement about the central axes of the bushing and rod191. The stop member may be biased pivotally, such as by a coil spring.Accordingly, the stop member may be engaged and pivoted inward(clockwise at 206 in FIG. 10), with an engaging force, and then mayspring outward to its extended position when the engaging force isremoved.

Example 2 Rail with Stops Adjustable for Beveled Ends of Workpieces

FIG. 12 shows an exemplary rail 210 including a pivotable stop 212 thataccommodates workpieces 214 and 216 with ends formed at distinct angles.Stop 212 may be pivotable about a vertical axis 218 and may be biasedtoward alignment with the frame of the rail assembly (clockwise motionin the present illustration) or may be biased toward an orthogonaldisposition relative to the frame. In any event, the stop may be pulledout (e.g., by hand) to various angles to engage workpieces with abeveled end (e.g., workpiece 214) or a square end (e.g., workpiece 216).

Example 3 Exemplary Gauge System with Folding Rail

FIG. 13 shows an exemplary gauge system 230 with a driver 231 and afolding rail 232 having a hinge mechanism 234 between each adjacent pairof frame sections 236. Stops 238 may be disposed intermediate the hingemechanisms, as shown here, and/or may have about the same longitudinalpositions as the hinge mechanisms.

The disclosure set forth above may encompass multiple distinctinventions with independent utility. Although each of these inventionshas been disclosed in its preferred form(s), the specific embodimentsthereof as disclosed and illustrated herein are not to be considered ina limiting sense, because numerous variations are possible. The subjectmatter of the inventions includes all novel and nonobvious combinationsand subcombinations of the various elements, features, functions, and/orproperties disclosed herein. The following claims particularly point outcertain combinations and subcombinations regarded as novel andnonobvious. Inventions embodied in other combinations andsubcombinations of features, functions, elements, and/or properties maybe claimed in applications claiming priority from this or a relatedapplication. Such claims, whether directed to a different invention orto the same invention, and whether broader, narrower, equal, ordifferent in scope to the original claims, also are regarded as includedwithin the subject matter of the inventions of the present disclosure.

1. A system for positioning workpieces for processing, comprising: adriver; a rail assembly coupled to the driver for driven motion parallelto a positioning axis, the rail assembly including a frame and aplurality of stops arranged along the frame, the stops being movable inrelation to the frame such that individual stops can be engaged with anend of a workpiece to position the end at distinct distances from apredefined site along the positioning axis; and a controller thatoperates the driver for movement of the rail assembly according toinputs that correspond to processing positions along workpieces, whereinthe rail assembly has an adjustable length.